Lightweight structural component in particular for aircraft and method for its production

ABSTRACT

Lightweight structural component including at least one panel and at least one stiffening element oriented one of lengthwise and crosswise. The at least one stiffening element includes two side pieces. Each of the two side pieces is at least partially connected to the panel in a material-locking manner. The two side pieces are connected to the panel at two separate joint zones. A method of producing the lightweight structural component includes milling the at least one panel to form at least one thickened region and joining the two side pieces to the at least one panel at the two separate joint zones. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of parent U.S.patent application Ser. No. 10/757,419 filed on Jan. 15, 2004, thedisclosure of which is expressly incorporated by reference herein in itsentirety. The present application also claims priority under 35 U.S.C.§119 of German Patent Application No. 103 01 445.4, filed on Jan. 16,2003, the disclosure of which is expressly incorporated by referenceherein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the design and production of lightweightstructural components. Objects in which its application is expedient andpossible are all large-volume lightweight structures in which anessential part of the bearing pressure occurs as area load via skinsheets and which are provided with stiffening elements for loaddistribution, load diversion, reduction of deflection or prevention ofdenting or buckling. Typically such cases of stressing are particularlymarked in many lightweight structures that are acted on by a pressuredifference between the outside and the inside of the skin sheet inaddition to the structural load. The invention can be used particularlyadvantageously for aircraft structures, in particular for fuselagestructures, but also for wing structures, engine intakes, pressurebulkheads, landing gear shaft covers, etc. Other fields of applicationlie in liquid tanks or gas tanks, pressure tanks or vacuum tanks,components of rockets and rocket engines and fuselage structures oflightweight watercraft.

2. Discussion of Background Information

Without restricting the generality, the prior art and the background ofthe invention will be explained by way of example based on theconstruction of aircraft fuselage structures. Usually aircraft fuselagesare produced from riveted panels that are reinforced by rivetedstiffening elements-respectively stringers running lengthwise along thefuselage pipes and ribs running in the circumferential direction.Typically a stringer comprises a suitably formed stringer head, astringer bar and a stringer base resting on a panel base at an angle of90° relative to the stringer bar, which stringer base is riveted to thepanel base.

The stress on the panel/stiffening element structure is very complex dueto the different load originations and the static and cyclical loadsdependent on many parameters. In the design of aircraft fuselagesconstructed in such a way, preset static strength demands must be met,fatigue strengths taken into account and safety guaranteed with regardto different preset critical failure scenarios. In the embodiment of theaircraft fuselage as a riveted structure, these demands are taken intoaccount through the location-dependent and loading-dependent selectionof the thickness of panel, stringers, ribs, the shape and the spacing ofstringers or ribs, the dimensions of panel base and rivets and rivetspacing, etc. The fact that weight-saving potentials in terms ofconstruction methods have been largely exhausted and that the productionof this type of differential structure is too expensive because of thelimited riveting speed and, in addition, can hardly be improved on inqualitative terms, have a negative impact on the design of theconventionally riveted structure.

It is known, for example, from P. Heider: Lasergerechte Konstruktion undlasergerechte Fertigungsmittel zum Schweiβen groβformatigerAluminium-Strukturbauteile in: VDI-Fortschrittsberichte, series 2:Fertigungstechnik, no. 326, VDI-Verlag Düsseldorf (1994) to replaceriveting by welding the stringer foot to the panel base from both sidessimultaneously by means of two lasers. In order to realize thisconnection with a sufficiently well-developed root of the weld seam andin a manner low in pores, it is necessary for both laser beams toproduce a common melting bath. This is achieved in that the two laserbeams, placed opposite one another, are focused on identical positionswith respect to the joint. Hot cracks are thereby avoided through theuse of suitable wire-shaped weld fillers, such as, e.g., wire of thealloy AlSi12. Through the very low linear energy of the process and theenergy input symmetrical to the stringer, the deformation is limited.

In another embodiment of this principle the construction of completelywelded shell components is possible, including stringers, ribs, clips,distribution belts and rib heads. See, for example, P. Brinck et al.:Schalenbauteil für ein Flugzeug und Verfahren zur Herstellung, PS DE 19844 035 C1.

Despite better static strength and higher rigidity compared with ariveted connection, the disadvantage of a connection produced in thisway lies in its lower damage tolerance which is manifested by, e.g., ahigher rate of crack growth of a circumferential crack after crossingthe stringer and a lower residual strength. The reason for this is that,on reaching a welded-on stiffening element, a crack spreads out into thelatter. Whereas with a conventional differential construction, the crackgrowth in the fuselage planking is delayed through the riveted oradhered reinforcements, such as stringers or ribs, since the crack tipdoes not spread into the stiffening elements for a certain number ofload cycles and, moreover, is held together through the intactreinforcement, in the welded-on stiffening elements the crack grows inthe planking and the stiffening element simultaneously, without anoticeable crack-delaying effect occurring. The weight-saving use oflaser beam-welded fuselage shells is thus only possible for fuselageregions for which the design criteria for damage tolerance do not needto be met, i.e., only for the lower shells of the fuselage.

The reason for this defect or disadvantage is that the known integralembodiments of the connection of the stiffening elements does notprovide any adequate geometric, stress-related or microstructuralpossibilities for stopping a crack, a less damaging crack branching oran energy dissipation near the crack opening. The crack can thus spreadunhindered into the stiffening elements.

Another defect or disadvantage is that the direct tensile strength of astringer/panel connection laser beam-welded from both sidessimultaneously decreases with increasing weld seam depth, i.e., withincreasing stringer thickness.

The reason for this is, i.a., to produce greater weld seam depths theweld parameters have to be changed such that a greater linear energy andmore unfavorable ratios of wire conveying speed of the weld filler towelding speed have to be selected. Together with solid state mechanicalinfluences, both of these lead to a greater under-matching in thewelding zone, a broader overaged region in the heat affected zone and toan increased risk of formation of micro-hot cracks.

To improve the crack growth behavior of shell components with welded-onstiffening elements, it has become known from, for example, F. Palm:Metallisches Schalenbauteil, PS DE 199 24 909 C1 to increase thethickness of the bar of the stiffening element near the welding zonewithout increasing the connection depth of the laser beam weld seam madefrom both sides simultaneously. In other embodiments of the invention areduced weld seam depth is made or notches placed between the weld seamand the increased thickness. The object of all three measures is to makeit more difficult for a crack to spread in the direction of the stringerhead. The crack can possibly be deflected and can run for a certaindistance in the weld seam or along the weld seam.

The disadvantage of this solution is that this embodiment is only gearedto the two bay crack type of stress, i.e., the bearing of a longitudinalor circumferential crack over two rib sections or stringer divisions.Both for the “tension in the direction of the head of the stiffeningelement” type of stress, such as occurs in the lower fuselage region andfor ribs, and for the combined “bending with bending deflectioncrosswise to the stiffening element” and “tension in the direction ofthe head of the stiffening element” types of stress, as occurs in theareas of the fuselage loaded by transverse stress, the proposed solutionleads to a reduction of the bearable loads or to a premature stringer orrib rupture.

The reason for the defect is that the two disadvantages of an integrallywelded structure—the lack of an effective mechanism for delaying cracksand the locally increased crack growth rate in the weld seam—arecombated only with disadvantageous consequences regarding loadingcapacity for other types of stress, or cannot be combated at all.

An embodiment of a welded arrangement of panel and reinforcing elementsthat achieves an increase in residual strength and thus is also intendedto render possible the use of welded fuselage shells for the side andupper shell area of the fuselage is known from H. J. Schmidt (PS DE 10031 510 A1). To this end reinforcements are applied to the stiffeningelements before the laser beam-welding. The reinforcements can therebybe arranged as doubler plates or as tension bands.

The doubler plates comprise high-strength Al alloys or fiber-reinforcedmetal laminates and are attached by riveting or an adhesive bond. Thedoubler plates must thereby be an adequate distance from the weld seam,which distance is determined by the temperature field of the weldingprocess. The tension bands comprise high-strength steel alloys ortitanium alloys or fiber composites and are inserted and twisted intothrough bores that are to be made beforehand. Cross sectionreinforcements are provided in the lower bar area of the stiffeningelement to contain the through bores. Another variant provides embodyingthe lower bar area in a slotted manner, inserting the tension bandthrough a mounting opening in the slotted lower bar area and connectingthe inserted tension band to the tension band in a form-locking mannerby compressing the slotted bar area and subsequently connecting it tothe skin sheet by laser beam welding in a known manner.

An increase in residual strength is achieved through the crack-delayingeffect of the reinforcements. This occurs in that the number of the loadcycles necessary for the complete severance of the stiffening element isincreased and the reinforcing element does not fail until after thestiffening element. Through the latter effect the reinforcing elementcan reduce the crack opening angle and reduce the tensions at the cracktip for the period between the failure of the stiffening element and thefailure of the reinforcing element.

The embodiment of the weld seam itself is not changed with respect tothe previously known prior art. This means that the stringer or rib footis attached to the skin sheet across its entire width by a single weldseam, whereby the weld seam is produced by laser beam welding from bothsides simultaneously.

One defect of the arrangement is that it is not suitable for improvingthe prior art with regard to the two critical stress types “tension inthe direction of the head of the stiffening element” and “bending in thedirection crosswise to the stiffening element.” The danger of staticfailure as a result of the separation of the stiffening element from thepanel, in particular during transverse stress in the side shells,therefore remains.

The reason for this is that the unchanged weld seam arrangement and weldseam vicinity cannot bear any greater direct tensile stress or bendingstress crosswise to the longitudinal directions of the stiffeningelements.

Moreover, it has a disadvantageous effect that the reinforcements of thestiffening elements do not reduce the local crack growth rate in theweld seam and its direct vicinity. This applies in particular to stresstypes such as, e.g., transverse stress in which there is a danger of acrack spreading along the weld seam.

The reason for this is that, for reasons determined by the process andthe arrangement, they have to be installed at a distance from the weldseam at which their effect in terms of stress relief for the weld seamis very slight.

Another defect is that the reinforcing elements cannot be applied to orinserted in the stiffening elements in an economic manner.

The reason for this is that additional production steps, such as, e.g.,riveting the doubler plates, adhering the doubler plates or drillingvery long through bores are necessary to apply the reinforcements, whichsteps are in themselves very expensive or in part even more expensivethan the riveting of the stiffening elements to the panel which is to bereplaced.

Furthermore, the fact that the variant with inserted tension bands isnot suitable for ribs has a disadvantageous effect. The reason for thislies in the impossibility of drilling a curved slot or of bendingtogether the two side pieces of the slotted lower bar area afterinserting the tension band in a plastic manner without damage to thematerials or a permanent deformation of the entire stiffening element.

SUMMARY OF THE INVENTION

The invention is directed to a new kind of lightweight structuralcomponent in particular for aircraft and a method for its effective andlower-cost production that is also suitable for complex stress types. Itis applicable for both straight and curved stiffening elements, featuresan improved damage tolerance, direct tensile strength, transverse stressloading capacity and bending resistance, and can be used even withthicker stiffening elements. Moreover, it does not require expensiveadditional separate production steps.

The invention is also directed to a lightweight structural componentthat, despite integral embodiment, features a differential failurebehavior, that leads to reduced load stresses and strains in the jointzone and its immediate vicinity and that can be produced simply withmodern manufacturing methods.

The invention also takes account of the following:

-   -   The embodiments of integral lightweight structures, and here in        particular aircraft fuselage structures, known according to the        prior art, do not adequately exploit the possibilities of        jointing technology due to a constructional design not suitable        for welding;    -   It is also possible to execute integral structures with locally        effective elements that avoid the weld seam weak point and        produce a differential failure scenario; and    -   A sufficiently faultless welding is possible even without a        laser beam-welding from both sides simultaneously with a common        melting bath, if new laser beam sources with the highest beam        quality and suitable, process-adapted beam formation (twin spot        or elliptical beam) and suitable weld fillers are used.

According to one aspect of the invention, in contrast to all previoussolutions known according to the prior art, the bar of the stiffeningelement on its side facing the skin sheet comprises not one foot but twospatially separate side pieces, both of which are connected to the panelin a material-locking manner by way of two separate joint zones. Thisarrangement has the advantages that with the same weight a clearlystiffer arrangement is realized which, compared with the previoussolution, reduces the mechanical stress due to direct tension andbending in the weld seams, reacts in a less sensitive manner to weldingdefects and is much less demanding in terms of the requirements ofprecision control of the two laser beams relative to one another.

For higher stresses, such as those that normally prevail, e.g., inaircraft construction, the panel is embodied so that it features athickening in the region of the junction points of the joint zones.

The stiffening elements can be embodied as stringers or as ribs in theembodiment of the structural component according to the invention.

The inventive concept is not limited to the joint zone necessarily beinga laser weld seam. The joint zones can just as well comprise frictionstir welded zones or adhered zones.

Through a local thickening of the skin sheet-here embodied as a skinstiffening base—the crack growth rate in the “circumferential crack withbroken stringer” stress type can be clearly reduced while crossing thestringer. Through the supporting effect of the locally thickened skinsheet in particular the loading of the weld seam is reduced and thecrack growth rate in the first side piece is reduced. Moreover, the nowdivided crack tip has to travel greater distances on several paths untilthe second stringer side piece and the entire stringer bar and stringerhead are severed.

The invention also provides for an advantageous design of the geometricdimensions of the stiffening element and skin sheet arrangement.

The invention can also prove useful for all types of stress environmentsin which the stiffening elements can be arranged outside. In this casethe weld seam is not stressed by radial tensile forces. Through thebranching of the crack after it crosses the weld seam, the crack growthrate is locally reduced compared with the prior art.

The inventive concept does not relate only to the heads of thestiffening elements being embodied in the classic L-shape. Withoutviolation of the inventive concept, the stiffening profile can also beembodied, e.g., as a U-profile or as a profile similar to a U-profile.In this form, the head side of the U-profile can be connectedparticularly well to potentially necessary attachment parts. Embodimentsdisclosed herein further develop the geometric shape of the stiffeningelement for this case.

The invention also introduces a new additional variant for improvingdamage tolerance. They provide the arrangement of cut-outs within theside pieces of the stiffening element. If a running crack runs into oneof these openings, it can be stopped. The reason for this is that thevery high stress intensity factor at the crack tip is replaced by thelower notched form factor of the cut-out after the crack leads into thecut-out. In fact, this is equivalent to the necessity of a new start ofthe crack in a stress field with a lower stress concentration.

It is known from experiments that once a primary crack has formed underthe stress conditions of the two bay crack criterion, it is very hard todeflect it from its general crack growth direction. It can thereforehappen that with a conventional embodiment of the stringer, the crackruns between the two cut-outs and is even accelerated for a short timedue to the locally lower supporting effect. This is taken into accountby the staggered arrangement of the cut-outs in the two side pieces. Forthe lower fuselage region these cut-outs can advantageously be used asdrainage openings at the same time.

The fact that the load stresses are not distributed homogenously in anaircraft fuselage is allowed for in an advantageous manner. Thus inparticularly highly stressed areas the crack growth rate in the stringerfoot can be further reduced through the local application of a doublerplate made of a damage-tolerant, fiber-reinforced laminate. Inparticular in the case that the stiffening element is a rib, thereduction of the structural static load capacity can be compensated forby the cut-outs during tensile stress on the rib bar.

The invention also permits a new approach to reducing the load stress inthe joint zones. In the region of the upper shells of the fuselage, thejoint zones are subjected to a high tensile stress that can be clearlyreduced by stress relief elements arranged in their direct vicinity.

Disclosed embodiments also advantageously utilize the finding thatmaterial accumulations can reduce the crack growth in the panel in aparticularly effective manner if they are located in the direct vicinityof the panel. They contribute less to avoiding buckling because of theirlower moment of resistance, but they are sufficient to be able tosomewhat enlarge the spacing of the stiffening elements and thus to saveweight generally. Moreover, they are able to improve the acousticbehavior of the fuselage.

The invention also provides that if heads are arranged asymmetrically tothe longitudinal axis of the stiffening elements, the stiffeningelements deform crosswise to their longitudinal direction under tensilestress, compressive stress or transverse stress and thus generate highbending stresses in the weld seam.

The invention also provides an arrangement for a lightweight structuralcomponent in which a reinforcing element is located in the cavity thatis formed by the two side pieces of the stiffening element and the skinsheet, which reinforcing element comprises a material with a much highermodulus of elasticity than the skin sheet and the stiffening elementsand which is connected to at least one of the partners stiffeningelement or skin sheet in a form-locking and/or force-locking manner.During an elongation of the panel in the direction of the longitudinalaxis of the stiffening elements, the force-locking and/or form-lockingconnection between the reinforcing element and the stiffening element orthe skin sheet reduces the elongation in the foot area of the stiffeningelement and thus in the joint zones. Thus stress on the two weld seamsis relieved such that despite a microstructure in the weld zone thatpromotes the crack growth, a locally reduced crack growth rate results.Since the fatigue strength of the reinforcing elements that have notbegun to crack is much greater than the crack-spreading stress in theskin sheet and stiffening element, the reinforcing element still remainsintact even when the crack has crossed both side pieces of thestiffening elements and the panel stiffening base. In addition to areduction of the crack growth rate, the residual strength is alsoincreased. In comparison with the prior art it has a positive impact inthat the reinforcing element is located in the direct vicinity of theweld seam and thus can effectively reduce the stress concentrationduring the approach of the crack to the joint location between the paneland stiffening element. Thus the arrangement of the reinforcing elementsaccording to the invention is suitable for avoiding or reducing thedisadvantages of an integral structure with respect to damage tolerance.

The invention also provides process steps for producing the lightweightstructural component according to the invention. Embodiments relate tothe use of laser beam welding as the most favorable process variant. Inone embodiment the experience is utilized that the development ofwelding defects (pores, discharge) can be reduced with laser beamwelding of aluminum by a suitable beam formation.

The inventive concept further contemplates the joining to take place byfriction stir welding or adhesion.

The invention also provides a process that saves cycle time by way ofjoining from both sides simultaneously. However, in contrast to previousassumptions it is also possible to produce sufficiently faultless weldseams with weld seams welded unilaterally in succession and locatedseparately from one another. The fact that it is thus possible to omitthe simultaneous welding on both sides while forming a common meltingbath renders possible the constructional free spaces for the embodimentaccording to the invention of the lightweight structural component aswell as a simplified process cycle.

The invention also provides for methods with which the stiffeningelements according to the invention can be mechanically produced in anon-cutting manner in a particularly favorable way. According to oneembodiment extrusion is used as a very cost-effective method ofproducing the stiffening elements including their bars. If thestiffening element is embodied as a rib, this results in the difficultythat in the case of, e.g., an aircraft fuselage, it has to be embodiedin a curved manner. Such curved semi-finished products can also beproduced in a very favorable manner, if during extrusion a transverseforce is exerted on the semi-finished product immediately after theextrusion die. If the height of the stiffening element is too great inrelation to its thickness, it is more favorable to produce the two sidepieces by splitting by way of pressure rollers.

One process step is the production of the force-locking and/orform-locking connection between the stiffening element and/or skin sheetwith the reinforcing element. The invention also provides for favorablevariants for this.

The invention also provides for a lightweight structural component inparticular for aircraft comprising at least one skin sheet andstiffening elements arranged lengthwise or crosswise or lengthwise andcrosswise thereon, which stiffening elements are connected completely orat least partially to the skin sheet respectively by their foot in amaterial-locking manner, wherein the bar of the stiffening element onits side facing the skin sheet is composed of two side pieces that areboth connected to the panel in a material-locking manner by way of twoseparate joint zones.

The panel may feature a thickening in the region of the connectionpoints of the joint zones. The stiffening elements may be embodied asstringers running lengthwise. The stiffening elements may be embodied asribs running in the circumferential direction. The separate joint zonesmay be laser beam weld zones. The separate joint zones may be frictionstir weld zones. The separate joint zones may be adhered joint zones.

A panel stiffening base may be located between the inner surfaces of theside pieces, the thickness of which panel stiffening base d_(Hv) isgreater than the thickness d_(Hs) of the panel base and whose sidesurfaces are designed such that they rest on the inner surfaces of theside pieces and the two joint zones are embodied such that they extendup to the side surfaces of the panel stiffening base. The two sidepieces may be bent by a total angle α so that the inner surfaces of thetwo side pieces and the surface of the skin stiffening base form anisosceles triangle and the total angle α lies in the range 7°≦α≦50°. Thefollowing ratios apply for the dimensions of the stiffening element: theratio between the side piece thickness in the plane of the joint zonet_(s) and the thickness of the stiffening element d_(s) is0.5≦t_(s)/d_(s)≦1.8; the ratio between side piece length s_(s) and theheight of the stiffening element h_(s) is 0.15≦s_(s)/h_(s)≦0.7; theratio of the side piece thickness near the branching of the two sidepieces of the stiffening element b_(s0) and the side piece thickness inthe plane of the joint zone t_(s) is 0.28≦b_(s0)/t_(s)≦1; the angle βbetween the panel and the joint surface of the joint zone is 0°≦β≦25°.

The two side pieces may be bent at a total angle α=180° so that theinner surfaces of the two side pieces rest on the surface of the panelbase. The stiffening element may be formed from a generally U-profile,whereby the two side pieces extend directly up to the head of thestiffening element. The head of the stiffening element may extend onboth sides over the side pieces of the U-profile which run parallel. Thetwo areas of the head of the stiffening element extending over the sidepieces may each feature an edge area pointing in the direction of theskin sheet. The panel reinforcing base may be embodied in a dividedmanner and that the two lateral outer surfaces of the panel reinforcingbase rest on the inner surfaces of the side pieces. The two jointsurfaces and the outer sides of the panel stiffening base or feature asurface may be produced by metal cutting.

Cut-outs may be located in the two side pieces, which cut-outs arearranged at intervals a along the side pieces. The distance between theedging of the cut-outs and the joint surfaces may be greater than oneand a half times the side piece thickness t_(s) in the plane of thejoint zone. The cut-outs may be arranged displaced respectively by thedistance a/2. The cut-outs may feature a cylindrical form. The cut-outsmay feature the form of equal-sided or virtually equal-sided triangleswith rounded off corners, whereby the cut-outs are arranged along theside pieces so that the vertices of the triangles point alternately inthe direction of the panel and in the direction of the head of thestiffening element.

A doubler plate may be made of a damage-tolerant, fiber-reinforcedlaminate is attached on both outer surfaces of the two side pieces ofthe stiffening element. One to five stress relief elements may belocated inside the panel base symmetrical to the bar of the stiffeningelement and near the joint zones, which stress relief elements comprisea material with a much higher modulus of elasticity and higher fatiguestrength than the material of the skin sheet. The stress relief elementsmay be made of high-strength wire cables. One stress relief element maybe located directly beneath the panel stiffening base. The panelstiffening base may be made of the material expediently deformed duringthe rolling-in of the stress relief element. The panel bars may belocated on the panel parallel or perpendicular or perpendicular andparallel to the reinforcing elements. The height of the panel bars maycorrespond to the height of the panel stiffening base and the spacing ofthe stiffening elements on the skin base may be an integral multiple ofthe spacing of the panel bars. The head of the stiffening element may beembodied symmetrically and may be arranged centrally on the bar of thestiffening element.

The invention also provides for a lightweight structural component inparticular for aircraft, comprising at least one skin sheet andstiffening elements arranged thereon lengthwise or crosswise orlengthwise and crosswise. The stiffening elements are connectedcompletely or at least partially to the skin sheet respectively by theirfoot in a material-locking manner. Each bar of the stiffening elementson its side facing the skin sheet is made of two side pieces, both ofwhich are connected in a material-locking manner to the panel by way oftwo separate joint zones. The panel features a thickening in the regionof the connection points of the joint zones. A reinforcing element islocated in the cavity formed by the two side pieces and the panelstiffening base, which reinforcing element comprises a high-strengthmaterial with a modulus of elasticity that is greater than the modulusof elasticity of the materials of the skin sheet or of the stiffeningelements. The reinforcing element is connected to the two side piecesand/or the panel stiffening base in a force-locking and or form-lockingmanner.

The stiffening elements may be embodied as stringers running lengthwise.The stiffening elements may be embodied as ribs running in thecircumferential direction. The separate joint zones may be laser beamweld zones. The separate joint zones may be friction stir weld zones.The separate joint zones may be adhered joint zones.

The two joint surfaces and the outer sides of the panel stiffening basemay feature a machined surface.

A combined force-lock and form-lock may be realized in that the surfaceof the reinforcing element features a roughening or a surface profiling,the impression of which is on the two inner surfaces of the two sidepieces and/or the surface of the panel reinforcing base.

The cavity formed by the two side pieces and the panel stiffening base,and the cross section of the reinforcing element, may form an equalisosceles triangle with a rounded-off apex.

The reinforcing element may be embodied as a wire or a pipe, the panelstiffening base is embodied as a circle segment with the wire or pipediameter, and the branching of the two side pieces at the foot of thestiffening element is embodied such that it encloses the wire or thepipe at a looping angle of approx. 180° and the two side pieces lieparallel to one another, whereby the spacing of their two inner surfacescorresponds to the diameter of the wire or pipe.

The panel stiffening base may contain a recess to accept the reinforcingelement. The bar or the side pieces of the stiffening element mayfeature cut-outs that are arranged along the bar or along the sidepieces at intervals “a”. The cut-outs may be embodied in a circularmanner. The cut-outs may feature the shape of equilateral or almostequilateral triangles with rounded-off corners, whereby the trianglesare arranged along the bar or the two side pieces such that one apex ofthe triangles points alternately in the direction of the panel and inthe direction of the head of the stiffening element. The cut-outs may bearranged and/or displaced by the distance a/2 respectively.

Two or four stress relief elements may be located inside the panel basesymmetrical to the bar of the stiffening element and near the jointzones, which stress relief elements are composed of a material with amuch higher modulus of elasticity and higher fatigue strength than thematerial of the skin sheet. The stress relief elements may be composedof high-strength wire cables.

Panel bars may be located on the panel parallel or perpendicular orparallel and perpendicular to the reinforcing elements. The height ofthe panel bars may correspond to the height of the panel stiffeningbases and the spacing of the stiffening elements on the skin sheet is anintegral multiple of the spacing c of the panel bars. The head of thestiffening element may be embodied symmetrically and may be arrangedcentrally on the bar of the stiffening element.

The invention also provides for a method for producing a lightweightstructural component, in particular for aircraft, as described above,and made by the following stages: chemical or mechanical milling to makethe thickening of the skin sheet, extrusion of the stiffening elements,tensioning of the panel; symmetrical positioning of the stiffeningelement on the thickening of the skin sheet; tensioning of thestiffening element to realize a flat configuration of the jointsurfaces; and joining of the stiffening element to the skin sheet by wayof two separate joint zones with at least local mechanical tension.

The joining may be carried out by way of laser beam welding. The laserbeam focus may be formed such that it is extended in the feed directionor divided into two partial beams.

The joining may be carried out by way of friction stir welding. Thejoining may be carried out by adhesion. The joining of the two sidepieces or of the stiffening element to the skin sheet may be carried outfrom both sides simultaneously.

The two side pieces of the stiffening element may be joined to the skinsheet unilaterally in succession. The two side pieces may be embodiedwith the aid of and during extrusion. The stiffening element may be arib, the rib is extruded with such a radius that the radius that isfeatured by the two undersides of the side pieces corresponds to theradius of the inside of the panel base. The stiffening element may beconventionally extruded and the two side pieces may be produced by asubsequent splitting by way of press rollers.

Before the positioning of the stiffening element on the skin sheet, thereinforcing element may be inserted between the side pieces of thestiffening element or in the recess of the panel stiffening base and isconnected to the stiffening element or the panel stiffening base in aform-locking and/or force-locking manner by way of a mechanicaldeformation. The mechanical deformation may be carried out byrolling-in. The force-locking and/or form-locking connection between thestiffening element and the reinforcing element may be produced bycoextrusion. The mechanical deformation to produce the force-lockingand/or form-locking connection between the stiffening element andreinforcing element may be effected by tensioning technology directlybefore the joining process or in the course of the joining process.

The invention also provides for a lightweight structural componentcomprising at least one panel, at least one stiffening element orientedone of lengthwise and crosswise, the at least one stiffening elementcomprising two side pieces, and each of the two side pieces being atleast partially connected to the panel in a material-locking manner,wherein the two side pieces are connected to the panel at two separatejoint zones.

The component may be utilized in an aircraft. The at least one panel maycomprise a skin sheet. The at least one panel may comprise a thickenedregion in an area of the two separate joint zones. The at least onestiffening element may comprise a stringer which is oriented in alengthwise manner. The at least one stiffening element may comprise arib running in a circumferential direction. The two separate joint zonesmay comprise laser beam weld zones. The two separate joint zones maycomprise friction stir weld zones. The two separate joint zones maycomprise adhered to joint zones. The two separate joint zones maycomprise adhesive bonded joint zones. The at least one panel maycomprise a panel stiffening base having an outer portion and an innerportion arranged between inner surfaces of the two side pieces.

The panel stiffening base may comprise a thickness d_(Hv) of the innerportion is greater than a thickness d_(Hs) of the outer portion andwherein side surfaces of the inner portion rest against inner surfacesof the two side pieces. The two separate joint zones may respectivelyextend at least partially up to the side surfaces of the inner portion.The two side pieces may be bent away from each other by a total angle α,whereby inner surfaces of the two side pieces and a surface of the atleast one panel form a generally isosceles triangle. The angle α may liein a range of between approximately 7° and approximately 50°.

The at least one stiffening element may comprise the following: a ratiobetween a side piece thickness t_(s) in a plane of each joint zone and athickness d_(s) of the at least one stiffening element comprisesapproximately 0.5≦t_(s)/d_(s)≦approximately 1.8; a ratio between eachside piece length s_(s) and a height h_(s) of the at least onestiffening element comprises approximately0.15≦s_(s)/h_(s)≦approximately 0.7; and an angle β between the panel andeach joint surface of each joint zone comprises approximately0°≦β≦approximately 25°.

The at least one stiffening element further comprises the following: aratio of each side piece thickness b_(s0) near a branching of the twoside pieces and a side piece thickness t_(s) in a plane of each jointzone comprises approximately 0.28≦b_(s0)/t_(s)≦approximately 1.

The two side pieces may be bent or oriented at a total angle α ofapproximately 180°, whereby inner surfaces of the two side pieces reston a surface of at least one panel. The two side pieces may beintegrally formed with the at least one stiffening element, whereby theat least one stiffening element and the two side pieces comprise aone-piece member. The two side pieces may be integrally formed with theat least one stiffening element, whereby the at least one stiffeningelement and the two side pieces comprise a one-piece member. The atleast one stiffening element may comprise a generally U-shaped profile,whereby the two side pieces are arranged on opposite ends of a head ofthe at least one stiffening element. The two side pieces may be of thegenerally U-shaped profile and may be parallel to each other. The atleast one stiffening element may comprise an edge area which is orientedin a generally parallel manner relative to the at least one panel. Theat least one panel may comprise a panel reinforcing base portion whichcomprises a first base portion and a second base portion separated fromthe first base portion, wherein lateral outer surfaces of the first andsecond base portions rest against inner surfaces of the two side pieces.

An area of the at least one panel may comprise the two joint zoneswherein each joint zone comprises surfaces formed by metal cutting. Anarea of the at least one panel may comprise the two joint zones whicheach comprise surfaces formed by metal removal. At least one of the twoside pieces may comprise cut-outs. At least one of the two side piecesmay comprise a plurality of through openings. Each of the two sidepieces may comprise cut-outs and the cut-outs may be arranged atgenerally regular intervals “a”. Each of the two side pieces maycomprise through openings arranged at generally regular intervals “a”. Adistance between an edge of the through openings and joint surfaces ofthe two joint zones may be greater than approximately one and a halftimes a side piece thickness t_(s) measured in a plane of each jointzone. The through openings in one of the two side pieces may be spacedfrom each other by a distance “a” and wherein the through opening of theother of the two side pieces are spaced from the through opening of theone of the two side pieces by a distance of approximately a/2. Thethrough openings may comprise circular openings. The through openingsmay comprise polygonal openings. The through openings may comprisenon-circular openings. The through openings may comprise triangularopenings. The triangular openings may comprise approximately equal-sidedtriangular openings with rounded corners, whereby vertices of adjacenttriangular openings point in opposite directions.

The component may further comprise a doubler plate made of adamage-tolerant fiber-reinforced laminate attached on outer surfaces ofeach of the two side pieces.

The component may further comprise at least one stress relief elementlocated inside the at least one panel. The at least one panel maycomprise a thickened panel base arranged in an area of the two separatejoint zones and the at least one stress relief element may be arrangedwithin the thickened panel base. The at least one stress relief elementmay be arranged directly beneath a bar portion of the at least onestiffening element and between the two separate joint zones. The atleast one stress relief element may comprise a material with a highermodulus of elasticity and a higher fatigue strength than a material ofthe at least one panel. The at least one stress relief element maycomprise a plurality of stress relief elements. The at least one stressrelief element may comprise a plurality of spaced apart stress reliefelements. The at least one stress relief element may comprise ahigh-strength wire cable. The at least one stress relief element may belocated directly beneath a panel stiffening base of the at least onepanel and is centrally disposed between the two separate joint zones.The panel stiffening base may be integrally formed with the at least onepanel, whereby the panel stiffening base and the at least one panelcomprise a one-piece member.

The at least one panel may comprise a panel stiffening base made ofmaterial that is deformed during a rolling-in of a stress relief elementinto the panel. The at least one panel may comprise a panel stiffeningbase made of material that is deformed during a rolling of the panel.The at least one panel may comprise a plurality of panel bars arrangedgenerally parallel to one another and perpendicular to the at least onestiffening element. The at least one panel may comprise a plurality ofpanel bars arranged generally parallel to one another and generallyperpendicular to the at least one stiffening element. The at least onepanel may comprise a plurality of panel bars, some of which are arrangedgenerally parallel to one another and some of which are arrangedgenerally perpendicular to one another. The at least one panel maycomprise a plurality of panel stiffening bases and a plurality of panelbars, wherein a height of the panel bars corresponds to a height of thepanel stiffening bases, wherein the at least one stiffening elementcomprises a plurality of stiffening elements, and wherein a spacingbetween the stiffening elements is generally equal to an integralmultiple of a spacing “C” between the panel bars. The at least onestiffening element may comprise a head portion that is coupled to a barportion. The head portion may project from both sides of the barportion. The head portion may project by generally equal amounts fromboth sides of the bar portion.

The invention also provides for a lightweight structural componentcomprising at least one panel comprising at least one thickened region,at least one stiffening element arranged on the at least one panel in atleast one of a lengthwise and a crosswise direction, the at least onestiffening element comprising a bar portion and two side pieces, each ofthe two side pieces being at least partially connected in amaterial-locking manner to the at least one thickened region by twoseparate joint zones.

Each of the two side pieces may instead be non-removably and/or fixedlysecured to the at least one thickened region by two separate jointzones. The component may further comprise a reinforcing element locatedin a cavity formed by the two side pieces and a surface of the thickenedregion. The at least one thickened region may comprise a panelstiffening base and the reinforcing element may comprise a high-strengthmaterial having a modulus of elasticity that is generally greater than amodulus of elasticity of a material of at least one of the at least onepanel and the at least one stiffening element.

The reinforcing element may be connected to at least one of the two sidepieces and the at least one panel stiffening base in one of aforce-locking manner and a form-locking manner. The component may bearranged on an aircraft. The at least one stiffening element maycomprise a stringer running in a lengthwise direction. The at least onestiffening element may comprise a rib running in a circumferentialdirection. The two separate joint zones may comprise laser beam weldzones. The two separate joint zones may comprise friction stir weldzones. The two separate joint zones may comprise adhered or adhesionjoint zones. The two separate joint zones may comprise adhesive bondedjoint zones. The two joint zones may comprise panel surfaces andsurfaces of the two side pieces, and wherein each of the panel and twoside piece surfaces comprises a machined surface.

The reinforcing element may comprise surfaces which are bothforce-locked and form-locked to at least one of inner surfaces of thetwo side pieces and a surface of the thickened region. The surfaces maycomprise one of a rough profile and surface profiling. The reinforcingelement may comprise surfaces which are fixed to at least one of innersurfaces of the two side pieces and a surface of the thickened region.

The component may further comprise a cavity formed by the two sidepieces and the thickened region and a reinforcing element arrangedwithin the cavity. The cross-sectional shape of the cavity may generallycorrespond to the cross-sectional shaped of the reinforcing element. Thecavity may comprise a cross-sectional shape having a form of a generallyequal isosceles triangle with a rounded-off apex. The reinforcingelement may comprise a cross-sectional shape having a form of agenerally equal isosceles triangle with a rounded-off apex.

The component may further comprise at least one reinforcing elementarranged within the thickened region. The component may further compriseat least one reinforcing element arranged between the two side pieces,wherein the at least one reinforcing element comprises one of a wire, awire rope, a pipe and a tube. The at least one thickened regioncomprises a curved surface and wherein the two side pieces comprisescurved surfaces, whereby the curved surfaces enclose the at least onereinforcing element. The two side pieces may contact at leastapproximately 180° and/or half of the outer surface of the at least onereinforcing element. The two side pieces may comprise portions which arearranged parallel to one another, whereby a spacing between innersurfaces of the two side pieces generally corresponds to a diameter ofthe at least one reinforcing element. The at least one thickened regionmay comprise a panel stiffening base which contains a recess adapted toreceive a reinforcing element.

The component may further comprise a plurality of cut-outs arranged inat least one of the bar portion and the two side pieces, wherein thecut-outs are arranged at regular intervals “a”.

The component may further comprise a plurality of through openingsarranged in at least one of the bar portion and the two side pieces,wherein the through openings are arranged at regular intervals “a”. Thecomponent may further comprise a plurality of through openings arrangedin at least one of the bar portion and the two side pieces. The throughopenings may comprise a circular through openings. The through openingsmay comprise non-circular through openings. The through openings maycomprise polygonal through openings. The through openings may comprisegenerally approximately equilateral triangular through openings withrounded-off corners. Adjacent triangular through openings may beoriented in opposite directions. The through openings of one of the twoside pieces may be arranged offset from the through openings of anotherof the two side pieces, whereby a distance between the through openingsof each of the two side pieces comprises a value “a”, and whereby adistance between each of the through openings of one of the two sidepieces and each of the through openings of another of the two sidepieces comprises a/2.

The component may further comprise a plurality of stress relief elementsarranged within the thickened region. At least one of the plurality ofstress relief elements may be arranged on one side of the bar portionand at least another of the plurality of stress relief elements may bearranged on another side of the bar portion. At least one of theplurality of stress relief elements may be arranged near each of the twoseparate joint zones. At least one of the plurality of stress reliefelements may comprise a material having a higher modulus of elasticityand a higher fatigue strength than a material of the at least one panel.At least one of the stress relief elements may comprise a high-strengthwire cable. The at least one panel may comprise a sheet skin for one ofan aircraft, a boat and a ship. The at least one panel may comprise aplurality of panel bars. The plurality of panel bars may be arrangedgenerally parallel to the at least one stiffening element. The pluralityof panel bars may be arranged generally perpendicular to the at leastone stiffening element. The plurality of panel bars may be arrangedgenerally parallel and generally perpendicular to the at least onestiffening element. A height of the panel bars may correspond to aheight of the thickened region. The at least one stiffening element maycomprise a plurality of stiffening elements which are spaced apart fromone another by an amount equal to an integral multiple of a spacing “C”of the panel bars.

The at least one stiffening element may comprise a head which iscentrally arranged on the bar portion.

The invention also provides for a method of producing the lightweightstructural component of the type described above, wherein the methodcomprises milling the at least one panel to form at least one thickenedregion and joining the two side pieces to the at least one panel at thetwo separate joint zones.

The method may further comprise extruding the at least one stiffeningelement. The method may further comprise subjecting the at least onepanel to tension. The method may further comprise subjecting the atleast one stiffening element to tension.

The invention also provides for a method of producing the lightweightstructural component of type described above, wherein the methodcomprises milling the at least one panel to form at least one thickenedregion, extruding the at least one stiffening element, subjecting the atleast one panel to tension, subjecting the at least one stiffeningelement to tension, and joining the two side pieces to the thickenedregion at the two separate joint zones.

The joining may comprise joining the two side pieces to the at least onethickened region by laser beam welding. The joining may comprise joiningthe two side pieces to the at least one thickened region by laser beamwelding, and wherein a laser beam focus is formed such that it is one ofextended in a feed direction and divided into two partial beams. Thejoining may comprise joining the two side pieces to the at least onethickened region by friction stir welding. The joining may comprisejoining the two side pieces to the at least one thickened region byadhesion. The joining may comprise joining the two side pieces to the atleast one thickened region by adhesive bonding. The joining may comprisesimultaneously joining the two side pieces to the at least one thickenedregion. The joining may comprise unilaterally joining the two sidepieces to the at least one thickened region. The joining may comprisejoining the two side pieces one at a time to the at least one thickenedregion. The two side pieces may be formed by extrusion.

The method may further comprise extruding the at least one stiffeningelement and the two side pieces to form a one-piece extruded member. Themethod may further comprise forming the at least one stiffening elementas an extruded rib, wherein the two side pieces comprise inner curvedsurfaces, and wherein the thickened region comprises a curved surface.

The milling may comprise chemical milling. The milling may comprisemechanical milling. The milling may comprise HSC milling.

The method may further comprise extruding the at least one stiffeningelement and thereafter splitting the two side pieces by splitting usingpress rollers. The method may further comprise extruding the at leastone stiffening element and thereafter forming the two side pieces byrolling. The method may further comprise positioning a stiffeningelement between the two side pieces of the at least one stiffeningelement and a surface of the at least one thickened region.

The method may further comprise connecting a stiffening element to atleast one of the two side pieces of the at least one stiffening elementand a surface of the at least one thickened region. The method mayfurther comprise connecting by mechanical deformation a stiffeningelement to at least one of the two side pieces of the at least onestiffening element and a surface of the at least one thickened region.The mechanical deformation may comprise rolling-in. The connecting maycomprise at least one of force-locking and form-locking connecting.

The method may further comprise forming by co-extrusion the at least onestiffening element and a reinforcing element. The method may furthercomprise, before the joining, tensioning at least one of the at leastone stiffening element and the at least one panel. The method mayfurther comprise, during the joining, tensioning at least one of the atleast one stiffening element and the at least one panel.

The invention also provides for a method of producing the lightweightstructural component of the type described above, wherein the methodcomprises milling the at least one panel to form the at least onethickened region and joining the two side pieces to the thickened regionat the two separate joint zones.

The invention also provides for a method of producing the lightweightstructural component of the type described above, wherein the methodcomprises milling the at least one panel to form the at least onethickened region, forming as a one-piece member the at least onestiffening element and the two side pieces, and joining the two sidepieces to the thickened region at the two separate joint zones.

The invention also provides for a lightweight structural componentcomprising a metal panel comprising at least one thickened region, atleast one stiffening element coupled to a surface of the at least onethickened region, the at least one stiffening element being a one-piecemetal member and comprising at least a bar portion and two side piecesextending from the bar portion, the bar portion comprising a firstthickness, each of the two side pieces comprising a second thickness,the first thickness being greater than the second thickness, and ends ofthe two side pieces being at least partially connected to the at leastone thickened region by two separate weld joint zones.

The bar portion and two side pieces of the at least one stiffeningelement may form a generally Y-shaped cross-section. The bar portion andtwo side pieces of the at least one stiffening element may form agenerally T-shaped cross-section. The at least one stiffening elementmay have a generally I-shaped cross-section.

Other exemplary embodiments and advantages of the present invention maybe ascertained by reviewing the present disclosure and the accompanyingdrawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention,in which like reference numerals represent similar parts throughout theseveral views of the drawings, and wherein:

FIG. 1 shows a cross section of a lightweight structural component in afirst embodiment that is particularly simple to produce;

FIG. 2 shows a cross section of a structural component according to theinvention for higher demands with regard to damage tolerance;

FIGS. 3 a-c show a comparison of the bending stresses in a laserbeam-welded stringer/skin connection according to the prior art to thestringer/skin connection according to the invention;

FIGS. 4 a and 4 b show an alternative embodiment for the design ofstringers or ribs with integrated crack stoppers;

FIG. 5 shows a cross section through a stringer/skin connection that isembodied by an inserted reinforcing element for highest demands withregard to transverse stress capacity, damage tolerance and residualstrength;

FIG. 6 shows a cross section of the most highly stress-resistantstringer/skin connection in still another embodiment;

FIG. 7 shows a cross section of a highly stress-resistant stringer/skinconnection in still another embodiment;

FIG. 8 shows a cross section through an embodiment with additionalelements for stiffening the panel;

FIG. 9 shows a cross section of an embodiment in which the stiffeningelement is embodied as a U-profile;

FIG. 10 shows a cross section of an embodiment in which wire-shapedstress-relief elements are located inside the skin sheet in the directvicinity of the two weld zones;

FIG. 11 shows a cross section with a wire cable-shaped stress-reliefelement directly beneath the panel stiffening base;

FIG. 12 shows a cross section of a structural component according toanother embodiment of the invention;

FIG. 13 shows a cross section of a structural component according tostill another embodiment of the invention; and

FIG. 14 shows a cross section of a structural component according tostill another embodiment of the invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

The following are examples of non-limiting embodiments:

Example 1

The lower fuselage of an aircraft is to be embodied with a higher dentresistance and an improved stiffness. At the same time, production costsand weight are to be reduced. To this end, a riveted construction isreplaced by a laser beam-welded construction in a configurationaccording to the invention, as shown in FIG. 1 for the stringer/panelvariant.

The panel 1 includes a panel base 11. A stringer 2 normally embodiedwith a stringer head 12 and stringer bar 4 features on its side facingthe skin sheet 1 two side pieces 5, 6. The lower sides of the two sidepieces 5, 6 extend from the stringer foot 3 and run horizontally. Inthis way, they rest on a level panel base 11. Both side pieces 5, 6 areconnected in a material-locking and/or fixedly secured manner to thepanel base 11 with two separate joint zones 7, 8. The center-lines ofthe joints 7, 8 can form an angle of respectively γ=approximately 20° tothe surface of the panel base 11 (see FIG. 2). The joint zones 7, 8 areproduced by laser beam welding. The sum of the depths of the two jointzones can correspond to the stringer thickness d_(S). See FIG. 2 forillustration of this dimension.

The following exemplary dimensions are selected for the embodiment ofthe lightweight element shown in FIG. 1 (the dimensions are measured inthe same way as the corresponding dimensions in FIG. 2):

Panel thickness: d_(H)=approx. 1.6 mm, stringer height: h_(s)=approx.31.5 mm, thickness of the panel base: d_(Hs)=approx. 2.4 mm, width ofthe panel base: b_(Hs)=approx. 23 mm, side piece length s_(s)=approx.8.5 mm, stringer thickness d_(s)=approx. 3.3 mm, stringer head width:b_(s)=approx. 17.5 mm, side piece thickness in the plane of the jointzone and connection depth of the weld seams t_(s)=approx. 1.65 mm, anglebetween the two side pieces 5, 6 α=approx. 40°, spacing of the insideedges of the two side pieces on the panel base b_(rs)=approx. 3.0 mm.Both stringer and panel are produced from a weldable Al (aluminum alloy)material, in this case from alloy 6013 T4. The thickened panel base 11of the skin sheet 1 is preferably formed from the skin sheet by chemicalmilling, but may be formed by other acceptable material removing orsheet forming techniques. The stringers 2 which include the side pieces5, 6 are preferably formed by extrusion, but can be formed by otheracceptable techniques. Subsequently, the panel 1 is tensioned by way ofa vacuum tensioning device (not shown). By way of a following tensioningunit integrated in the welding head, the stringer 2 is positionedsymmetrically on the panel base 11 and pressed on the panel 1 by theapplication of a force of approx. 20 kg. Through lateral rolling, theposition of the two side pieces 5, 6 relative to one another isprevented from changing due to the compressive force or due to lateralforces caused by the alignment of the stringers 2 on the panel 1.

Joining is carried out with two CO₂ lasers using a power of approx.2,800 W (watts) each. Work is performed with wire-shaped weld filler ofalloy AlSi12 to avoid hot cracks. The welding wire has a diameter ofapprox. 0.8 mm and is fed at a wire feed speed of approx. 4,500 mm/min.The welding speed is 4 400 mm/min. To minimize distortion, welding takesplace from both sides simultaneously. The angle γ=approx. 20° and is setas the angle γ between the laser beam axis and surface of the panel 1.

According to the experts, e.g., Heider Lasergerechte Konstruktion undlasergerechte Fertigungsmittel zum Schweiβfen groβformatigerAluminium-Strukturbauteile in VDI—Fortschrittsberichte, series 2:Fertigungstechnik, no. 326, VDI-Verlag Düsseldorf (1994), the disclosureof which is hereby expressly incorporated by reference in its entirety,a stringer/skin connection that is low in welding defects (hot cracking,porosity, discharge) can only be achieved through welding from bothsides simultaneously while guaranteeing a common melting bath of the twolaser beams.

However, recent tests have shown that crack-free weld seams that are lowin pores and free of discharge can also be achieved by way of a suitablebeam formation of the normally circular laser beam focus. The separationof the laser beam into two beams lying one behind the other in the feeddirection has proved to be particularly favorable. A twin spot mirror istherefore used to avoid discharge and to reduce porosity. Approx. 0.3 mmis selected as the spacing of the foci with a division of the two powerportions in a ratio of approx. 60:40 with a laser power of approx. 3,500W.

After adjusting all the parameters, the welding process is started andthe joint line is traced in a CNC-controlled manner with the stringertensioning unit following. After welding, the panel 1 is conditioned,i.e., artificially aged to condition T6.

The ribs can also be embodied with identical geometric dimensions apartfrom the height and head of the stiffening element 2. In addition itshould be ensured hereby that the panel 1 is curved with a radiusR=approx. 2,820 mm. This means that the ribs have to be embodied in acurved manner such that the lower side of the two side pieces 5, 6describes a cylinder shell with the same radius. This is realized inthat during extrusion a transverse force is exerted in the direction ofthe rib head after the extrusion die. In process terms, the joining ofthe ribs takes place analogously to that of the stringers.

As a result of this, a stiffer aircraft fuselage lower shell, that ismore resistant to buckling and cyclical compressive loading, isadvantageously obtained in a manner that is quicker, morecost-effective, and without increased weight compared with riveting.

In this simplest embodiment the lightweight element according to theinvention is also very suitable for the production of stiff aluminumbodies of watercraft, in particular sport and racing boats. Other veryadvantageous applications include pressure tanks and vacuum tanks.

Example 2

Further advantages of the invention are to be explained on the basis ofa further developed embodiment that leads to a clearly improved damagetolerance behavior. It is particularly suitable for the side fuselagearea but also for the upper fuselage area, i.e., for transverse stressand/or tensile stress.

One preferred geometric embodiment is shown in FIG. 2. In addition tothe features specified in exemplary embodiment 1, the panel 1 alsofeatures a panel stiffening base 13. The two outer sides 16 of the panelstiffening base 13 are inclined at an angle of approx. a/2 and are thusadapted to the inner sides of the side pieces 5, 6 that are alsoinclined at an angle of approx. a/2 from the symmetric line (i.e., thecenter line running through stringer bar 4). The joint surfaces 9, 10 ofthe base 13 and of the two side pieces 5, 6 are inclined at an angleβ≧approx. α/2 with respect to the surface of the panel 1. With a weldseam angle γ≈β, the weld seam thus lies generally perpendicular oralmost perpendicular to the outer surface of the side pieces 5, 6. Incontrast to exemplary embodiment shown in FIG. 1, here the side pieces5, 6 are embodied with varying thickness and/or are tapered towards theside piece foot, i.e., the side piece thickness in the plane of thejoint zones t_(S) is greater than the side piece thickness b_(S0) nearthe branching point 14 of the two side pieces 5, 6.

This stringer/skin connection is, e.g., designed with the followingdimensions: stringer height h_(s)=approx. 37 mm, stringer head widthb_(s)=approx. 21 mm, stringer thickness d_(s)=approx. 4.4 mm, thicknessof the panel d_(H)=approx. 2.4 mm, thickness of the panel based_(Hs)=approx. 3.4 mm, thickness of the panel stiffening element 13d_(Hv)=approx. 5.0 mm, width of the panel base b_(Hs)=approx. 15.2 mm,width of the panel stiffening base b_(rs)=approx. 9.2 mm, side piecethickness near the branching point of the two side pieces b_(s0)=approx.2.2 mm, side piece height s_(s)=approx. 11.0 mm, side piece thickness inthe plane of the joint zone and simultaneously connection depth of theweld seam t_(s)=approx. 2.7 mm, angle between the two side piecesα=approx. 40°, angle between the joint surface 7, 8 and the panelβ=approx. 22.0°, radius in the branching point 14 is approx. 0.6 mm.

Apart from the manufacture of the panel stiffening base 13, theproduction steps run analogously to those in example 1. To guarantee amatching configuration between the inner sides of the two side pieces 5,6 and the side surfaces of the panel stiffening base 13 and the jointsurfaces 9, 10, this section is worked by HSC milling on the panel 1previously produced by chemical stripping. However, it is also possibleto omit the chemical stripping completely and to produce the entirethickness profile of the skin sheet 1 by HSC milling.

The following values have been selected as welding parameters: laserpower approx. 2,800 W, welding speed approx. 4,000 mm/min, wire feedspeed approx. 4,000 mm/min. The inclination of the laser beam axis tothe surface of the panel is adjusted according to the inclination of thejoint surfaces to γ=approx. 22.2°. All the other welding parameters areselected analogously to those of example 1 as described above.

The lightweight fuselage shell thus produced features particularly highvalues with regard to direct tensile strength, dent stability andbuckling stability as well as damage tolerance.

Compared with the normal variant that is laser beam-welded from bothsides simultaneously and that has the same stringer thicknessd_(s)=approx. 4.4 mm, the direct tensile strength is increased fromapprox. 230 MPa to approx. 325 MPa. Moreover, the scatter width of thedetermined cross tension values is significantly reduced. Regardless ofthe higher direct tension values, with comparable loads the materialstrain in the weld seam plane in the variant according to the inventionis lower because the connection width is increased from approx. 4.4 mmto approx. 2×2.7 mm=approx. 5.4 mm.

In this case the following ratios are realized according to oneembodiment: t_(s)/d_(s)=approx. 0.61; b_(s0)/t_(s)=approx. 0.81;s_(s)/h_(s)=approx. 0.30; β=approx. 22°. In the event that a subsequentartificial aging is to be omitted, the side piece thickness in the planeof the joint zone and connection depth of the weld seam t_(s) can beincreased to t_(s)=approx. 4.9 mm. The following would thus apply withthe other geometric parameters kept constant: t_(s)/d_(s)=approx. 1.11;b_(s0)/t_(s)=approx. 0.45.

The improvement regarding the use in fuselage shells loaded bytransverse stress is explained in FIGS. 3 a-c. Through the asymmetricalembodiment of the stringers, a bending moment M in the direction of thebent end of the stringer head 12 acts on the stringer (see FIG. 3 a)both during a tensile stress and during a compressive stress and in aparticularly marked manner during a transverse stress. The cross sectionstressed the most thereby lies in the weld seam. The force F associatedwith the bending moment leads to an effective bending stress at the weldseam surface of

$\begin{matrix}{\sigma_{Beff}^{a} = \frac{6*\alpha_{KB}*F*h_{S}}{L*d_{S}^{2}}} & (I)\end{matrix}$

with α_(KB) as a notched form factor for bending in the position of theweld seam and L as panel or stringer length.

In the solution according to the invention, however, the cross sectionstressed most in terms of bending no longer lies in the weld seamitself, but in the plane of the side piece branching (see FIG. 3 c). Dueto the changed leverage conditions and the much larger notch radiuscompared with the weld seam, the effective bending stress in the moststressed area is reduced to

$\begin{matrix}{\sigma_{Beff}^{c\; 0} = \frac{6*\alpha_{KB}^{r}*F*\left( {h_{S} - s_{S}} \right)}{L*d_{S}^{2}}} & ({II})\end{matrix}$

with α^(r) _(KB) as a notched form factor for bending at the site of theside piece branching with the radius r. If the tensions in therespectively most highly stressed cross sections in terms of bending arecompared, the result is the following diminution factor R₁:

$\begin{matrix}{R_{1} = {\frac{\sigma_{Beff}^{c\; 0}}{\sigma_{Beff}^{a}} = \frac{\alpha_{KB}^{r}*\left( {h_{S} - s_{S}} \right)}{\alpha_{KB}*h_{S}}}} & ({III})\end{matrix}$

With the above values of the geometric dimensions and α_(KB)≈3, α^(r)_(KB)≈1.1, a stress diminution factor of R₁≅0.26 results. This meansthat the highest effective bending stress is reduced to approx. 26%through the embodiment according to the invention and in addition isdisplaced from the weld seam to a region that is not microstructurallydamaged.

The bending stress in the weld seam due to the supporting effect of thelower side piece in FIG. 3 c is approximately replaced by a tensilestress σ^(c) _(Zeff) at

$\begin{matrix}{\sigma_{Zeff}^{c} = \frac{\alpha_{KZ}*h_{S}*F}{s_{S}*t_{S}*L*{\sin \left\lbrack {2*{arc}\; {\tan \left( {{b_{rs}/2}*s_{S}} \right)}} \right\rbrack}}} & ({IV})\end{matrix}$

(with α_(KZ) as notched form factor for tensile stress at the site ofthe weld seam).

Analogously to the diminution factor R₁, a diminution factor can also bedefined for the stress in the weld seam R₂ due to the effect of thebending moment M:

$\begin{matrix}{R_{2} = \frac{\sigma_{Zeff}^{c}}{\sigma_{Beff}^{a}}} & (V) \\{R_{2} = \frac{\alpha_{KZ}*d_{S}^{2}}{6*\alpha_{KB}*s_{S}*t_{S}*{\sin \left\lbrack {2*{\arctan \left( {{b_{rs}/2}*s_{S}} \right)}} \right\rbrack}}} & ({VI})\end{matrix}$

With the values given in example 2 and α_(KZ)≈α_(KB), in a roughcalculation the result is R₂=approx. 0.15. This means that with thesolution according to the invention the bending moments on the weld seamresulting from the asymmetrical design of the stringers are very slightand, in contrast to the previous solution, a deterioration of theproperties can be ruled out.

To sum up this means that the material strain as a result of compressivestress, transverse stress or tensile stress in the critical weld seamarea is reduced and that laser beam welded integral structures can thusalso be used for side and upper shells.

Compared with the solution according to the invention, other solutionsfor reducing material strain caused by bending, such as, e.g., athickening in the stringer bar or the thickening of the stringer footaccording to FIG. 3 b are much less effective. If, for example, only thestringer foot is thickened, the direct tensile strength is reduced andthe bending stress in the weld seam, reduced but still present, reducesloading capacity in particular during transverse stress or tensilestress. Moreover, the fact that much greater weld seam depths arenecessary to compensate for the reduction in direct tensile strengths,which seam depths lead to an increase in deformation, has a negativeeffect.

With the stress type “crack growth with broken stringer,” the fact thatthe panel stiffening base 13 reduces the stress concentration near thecrack tip in the direct vicinity of the weld seam has a positive effect.The weld seam is thus subject to a reduced elongation amplitude, whichleads to a locally lower crack growth rate. Even after the failure ofthe weld seam in the first side piece, the crack growth rate is reducedby the crack branching and the material thickening in the skin sheet.Moreover it is important that the stringer still does not lose itsstabilizing effect even after the failure of the first weld seam and ofthe first stringer side piece. Overall, an improved damage tolerance andresidual strength are thus achieved.

Further advantages exist regarding the avoidance of unintentional damageto the weld seam during assembly of the fuselage panel, duringdisassembly of the fuselage interior or in the event of repair. Whereas,for example, with a stiffening element/skin connection carried outaccording to the prior art, an unintentional mechanical stress (e.g.,through bumping during assembly) crosswise to the stiffening element(rib or stringer) cracks can occur in the weld seam at an early stageeven before the development of any signs on the stiffening element(e.g., visibly permanent deformation), with suitable dimensions of thestiffening element according to the invention, the plane of the sidepiece branching can serve as desired deformation point that reactsbefore damaging stress or deformation conditions are reached in the weldseam.

From the point of view of quality assurance, the fact that—due to theseparate position of the weld seams—even maximum cross sectionweaknesses, such as those that can occur due to discharge or very longcommunicating pores, can cover no more than approx. 50% of the totalcross section of both weld seams, has a positive effect. The fact thatthe requirements for guaranteeing high quality, faultless weld seamshave been noticeably reduced has a very advantageous impact in weldingtechnology terms for the following reasons:

-   -   The foci of the two laser beams no longer have to meet exactly.        This reduces the requirements for precision control of the        welding equipment, in particular during the welding of parts        that are not flat.    -   Bond faults are easier to avoid because the angle between the        laser beam axis and the joint surface, which currently cannot be        reduced much under 20° due to the dimensions of the laser beam        weld heads, can be reduced to 0° because of the inclination of        the joint surfaces now possible. The requirements for precision        control of the laser beam perpendicular to the feed direction        and the risk of bond faults forming are thus also reduced.    -   Through the elimination of the previous demand for an angle        between joint surface and laser beam axis and the resulting        predetermined minimal weld seam width, a lower linear energy can        be used in welding, which reduces deformation.    -   From the point of view of welding technology, welding safety and        deformation, the requirement for welding from both sides        simultaneously can be eliminated.

For even more exacting demands on damage tolerance, the two side pieces5, 6 can be provided with cut-outs, as shown in a side view in FIGS. 4 aand 4 b. These cut-outs act as crack stoppers, since a crack penetratinginto them in order to spread further first has to initiate a new crack.Shape and size of the cut-outs 15′, 15″ are selected thereby such thatthey entail the lowest possible loss of stiffness in the longitudinaldirection of the stiffening element, while on the other hand acting asan effective crack stopper for a crack that has crossed the weld seam.The shape of the cut-outs can thereby be selected to be circular, oval,a slit or a rounded triangle. The cut-outs 15′, 15″ of the two sidepieces 5, 6 are thereby made in a manner displaced and/or offset from orrelative to one another. With only a small reduction in the stiffness ofthe stiffening element 2 it is thereby ensured that the crack leads outinto a cut-out, thus increasing the damage tolerance.

Example 3

Another variant for improving the damage tolerance of weldedpanel/stringer connections is explained in FIGS. 10 and 11.

High tensile stresses prevail in the upper shell area along the weldseams in a stringer/skin connection. They can be reduced by stressrelief elements embedded in the panel base parallel to the stringer. Inone preferred embodiment they comprise wires of high-strength steel,titanium or Ni materials. Their positive effect regarding damagetolerance is due to two effects: firstly, due to their higher modulus ofelasticity they put up a higher resistance to an elongation along thewire axis than the skin material surrounding them or the weld seam, sothey relieve the stress on their surroundings. The crack growth rate isthus reduced when the crack approaches the stress relief element andthus the weld seam. Secondly, the residual strength is improved, becausethe stress relief element still remains intact after the crack hascrossed the surroundings of the stress relief element.

According to the invention, several embodiments are possible. Accordingto FIG. 10, in a preferred embodiment, e.g., two multicore,high-strength wires 22 made of an Inconel alloy can be rolled (orotherwise placed) into the panel base directly to the right and left ofthe two weld seams. The effect of the relief of stress on the weld seamis particularly marked in this arrangement. A mechanically sufficientlyload-bearing connection of the stress relief elements to the panel isachieved through the rolling in and the structured surface of the wirecable.

In another arrangement shown in FIG. 11, the stress relief element 22 isrolled in (or otherwise placed) directly beneath the panel stiffeningbase. In this embodiment the insertion of the stress relief element 22can be coupled in a particularly favorable manner with the production ofthe panel stiffening base by way of metal forming.

Example 4

The exemplary embodiments shown in more detail in FIGS. 5 through 7 aredesigned for particularly exacting demands with regard to damagetolerance.

These embodiments utilize a reinforcing element 17 of a higher modulusof elasticity compared to the skin 1. The stiffening element material 17is located in the cavity formed by the two side pieces 5, 6 and thepanel stiffening base 13. In the exemplary embodiment, the reinforcingelement 17 is made of the titanium alloy Ti6Al4V. The modulus ofelasticity is approx. 110 GPa compared to the Al alloy used at approx.71 GPa. As shown in FIG. 5, the reinforcing element has the crosssection of an isosceles triangle with a rounded-off tip. An arrangementof intersecting grooves (not shown) can also be impressed in one or allof the surfaces of the reinforcing element 17 by way of rollerburnishing.

To realize the arrangement shown in FIG. 5, the same dimensions for thepanel 1 and stiffener 2 can be selected as in exemplary embodiment shownin, e.g., FIGS. 1, 2 and 10. The dimensions of the reinforcing element17 can accordingly be as follows: Base width: b_(V)=approx. 9.2 mm,height: h_(V)=approx. 10.4 mm.

The process steps are likewise selected analogously to exemplaryembodiments described above such as, e.g., the embodiment shown in FIGS.1 and 2. In addition, the reinforcing element 17 can be rolled into (orotherwise placed into) the stringer 2 after the extrusion of thestringer 2.

The particular advantage of this solution variant with a reinforcingelement 17 in the direct proximity of both the weld seams is that duringa stressing of the panel in the direction of the stringer longitudinalaxis, the elongation in the direct proximity of the weld seam is reducedby the lower elongation of the reinforcing element due to the greatermodulus of elasticity and the form-locking or force-locking connectionto the stringer. This results in a reduction of the longitudinal tensilestresses in the weld seam. An estimate with the above-mentionedgeometric parameters gives a stress diminution in the proximity of theweld seam of approx. 6%. Due to the strong dependence of the crackgrowth rate on the main stress in the critical stress area of 95 MPa,the result is a clear extension of the service life.

Furthermore, despite the placing of cut-outs 15′, 15″ in the side pieces5, 6 of the stringers 2, which can be used in the embodiments shown inFIGS. 5-7, the stiffness of the stringers is not reduced compared withthe prior art, so the crack stop function is possible without otherdisadvantageous consequences, such as reduction of the stiffness of thepanel or reduced support function of the stringers.

Due to its higher cracking fatigue strength, the reinforcing element 17is still intact even when the crack has crossed both weld seams. Thistemporarily reduces the crack growth rate even after the stringer hassubsequently cracked. With increasing crack growth, a load rearrangementoccurs on the reinforcing element 17 of the cracked stringer untilfinally, progressing along the stringer, the force-locking orform-locking connection to the stringer is detached and the reinforcingelement is pulled out of the cavity with a consumption of energy.Through this differential failure the residual strength is increased andthe damage development before the break is less catastrophic.

The reinforcing element 17 is embodied as a pipe or tube having acircular cross-section in the variant shown in FIG. 6. FIG. 7 presents avariant in which the reinforcing element 17 is rolled into (or otherwiseplaced in) the skin sheet 1 before welding of the stiffener 2 to thepanel 1. In this variant, the prevention of elongation in the weld seamby the reinforcing element 17 is particularly marked.

Because the weld seam is relieved from bending stress by the embodimentof the stringers 2 with two side pieces and the additional localstress-reducing effect of the reinforcing element 17, the stringer head12 can also be embodied with a greater thickness without a damagingeffect (see FIG. 8). This leads to a particularly stiff fuselage shell.For this case, alternatively the spacing of the stringers can also beincreased. To obtain larger spacing between stringers, it can befavorable to provide additional panel bars 19 in the panel at distances“C” from the stringer 2 or rib 2. These thickened panel regions orreinforcements 19 can be produced in a particularly simple manner bychemical milling.

Example 5

In some cases the stiffening elements 2 have to contain additionalattachment parts, load bearing elements or an inner skin in theirembodiment as ribs or as stringers. Without violating the inventiveconcept it can be advantageous for these applications to embody thestiffening element 2 as an upside-down U-profile. FIG. 9 shows asuitable embodiment. The two side pieces 5′, 6′ are thereby extended upto the head 12′ of the stiffening element 2. Another special feature isthat the panel stiffening base 13′, 13″ can be embodied in a dividedmanner, i.e., first and second panel base sections 13′ and 13″ tofurther save weight.

The embodiment shown in FIG. 12 is similar to the embodiment shown inFIG. 1 but utilizes a head 12 which extends generally parallel to thepanel 1 and which projects generally equally from both sides of the bar4. The head 12 may be integrally formed with the bar portion 4 andpieces 5, 6 or may be formed separately there from and then fixedlyattached to the bar portion 4 using, e.g., welding, rivets, fasteners,adhesive bonding, etc.

The embodiment shown in FIG. 13 is similar to the embodiment shown inFIG. 1 but utilizes a doubler plate DP made of damage-tolerant, fiberreinforced laminate pieces which are attached to the outer surfaces ofthe side pieces 5, 6. The doubler plates DP may be fixedly attached tothe pieces 5, 6 using, e.g., adhesive bonding, etc.

The stiffener embodiment shown in FIG. 14 utilizes a T-shaped end whoseside pieces 5, 6 are arranged generally parallel to one another, whichextends generally parallel to the panel 1, and which projects generallyequally from both sides of the bar portion 4. The head 12 may beintegrally formed with the bar portion 4 or may be formed separatelythere from and then fixedly attached to the bar portion 4 using, e.g.,welding, rivets, fasteners, adhesive bonding, etc. In this embodiments,the inner surfaces of the side pieces 5, 6 are fixedly attached to thepanel base 11 at two separate joint zones 7, 8.

It is noted that the invention contemplates any features shown in oneembodiment may be used in another embodiment. Thus, by way of example,the embodiment shown in FIG. 2 may use the T-shaped head 12 shown inFIG. 12 in place of the L-shaped head. The embodiments shown in FIGS. 1,2, and 5-14 may utilize the cut-outs shown in FIGS. 4 a-b or thecut-outs 20 of FIG. 7 in any desired arrangement. The head 12 in eachembodiment may be oriented in any desired angle relative to the barportion 4 instead of being generally perpendicular thereto and may beomitted altogether. Each embodiment may utilize any desired arrangementof reinforcements 17 and/or stress relief elements 22, including thedisclosed arrangements. Additionally, each embodiment may utilize thedoubler plates DP.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

LIST OF REFERENCE NUMBERS

-   1 Skin sheet, panel-   2 Stiffening elements, stringers, ribs-   3 Foot of the stiffening element, stringer foot, rib foot-   4 Bar of the stiffening element, stringer bar, rib bar-   5 Side piece 1-   5′ Side piece 1 if the stiffening element is embodied as a U profile-   6 Side piece 2-   6′ Side piece 2 if the stiffening element is embodied as a U-profile-   7 Joint zone 1-   8 Joint zone 2-   9 Connection point of joint zone 1, joint surface 1-   10 Connection point of joint zone 2, joint surface 2-   11 Thickening, panel base-   12 Head of the stiffening element, stringer head, rib head-   12′ Head of the stiffening element if the stiffening element is    embodied as a U-profile-   13 Panel stiffening base-   13′ Panel stiffening base if the stiffening element is-   13″ embodied as a U-profile-   14 Branching point of the two side pieces 5 and 6-   15′ Cut-outs in side piece 1 of the stiffening element-   15″ Cut-outs in side piece 2 of the stiffening element-   16-   16′ Outer sides of the panel stiffening bases 13, 13′, 13″-   16″-   17 Reinforcing element-   18 Recess in the panel stiffening base to accept the reinforcing    element-   19 Panel bar-   20 Cut-out in the bar of the stiffening element-   21 Laser beam axis-   22 Stress relief element-   DP Doubler plate-   a Spacing of cut-outs 15′ and 15″ in the side pieces 1 and 2-   a′ Spacing of the cut-outs 20 in the bar 4-   b_(Hs) Width of the panel base 11-   b_(rs) Width of the panel stiffening base, spacing of the two side    pieces 5 and 6 on the panel base-   b_(s) Width of the head of the stiffening element, stringer head    width-   b_(s0) Side piece thickness near the branching of the foot of the    stiffening element-   b_(v) Base width of the reinforcing element 17-   C Distance of the panel bar from the center line of the stiffening    element-   d_(H) Panel thickness-   d_(Hs) Thickness of the panel including panel base-   d_(Hv) Thickness of the panel including panel stiffening base-   d_(s) Thickness of the stiffening element, stringer thickness, rib    thickness-   F Force on stringer due to bending moment-   F_(v) Force at branching point due to bending moment-   h_(s) Height of stiffening element, stringer height, rib height-   h_(v) Height of reinforcing element 17-   M Bending moment on stringer-   R Curvature radius of the panel-   R₁; R₂ Stress diminution factors in the weld seam-   R Curvature radius of the transition between the bar of the    stiffening element 4 and the two side pieces 5, 6-   s_(s) Side piece height-   t_(s) Side piece thickness in the plane of the joint zone,    connection depth of the weld seam-   A Angle between the two side pieces 5 and 6-   α_(KB) Notched form factor for bending stress-   α_(KZ) Notched form factor for tensile stress-   α^(r) _(KB) Notched form factor for bending stress at the site of    the side piece branching-   B Angle between the joint surface of the joint zone 7 or 8 and panel    1-   Λ Angle between laser beam axis 21 and skin sheet-   σ^((a, b, c)) _(Beff) Effective bending stress acting on the weld    seam in embodiment (a, b, c)-   σ^((a, b, c)) _(Zeff) Effective tensile stress acting on the weld    seam in embodiment (a, b, c)-   σ^((a,b,c)) _(Beff) Effective bending stress acting on the    transition between the bar 4 of the stiffening element and the two    side pieces 5, 6 in embodiment (a, b, c)

1. A lightweight structural component comprising: at least one metalpanel; at least one metal stiffening element; the at least one metalstiffening element comprising two side pieces; each side piececomprising an outer surface, an inner surface, and an end surfaceextending between the outer and inner surfaces; and each end surface ofthe two side pieces being at least partially connected to the at leastone metal panel in a material-locking manner, wherein the two sidepieces are connected to the at least one metal panel at two separateweld joint zones, and wherein an axis passing through each side piecepasses through one of the two separate weld joint zones.
 2. Thecomponent of claim 1, wherein the component is utilized in an aircraftand the at least one stiffening element is oriented at least one of alengthwise and a crosswise direction relative to the at least one panel.3. The component of claim 1, wherein the at least one panel comprises askin sheet.
 4. The component of claim 1, wherein the at least one panelcomprises a thickened region in an area of the two separate weld jointzones.
 5. The component of claim 1, wherein the at least one stiffeningelement comprises a stringer which is oriented in a lengthwise manner.6. The component of claim 1, wherein the at least one stiffening elementcomprises a rib that runs in a circumferential direction.
 7. Thecomponent of claim 1, wherein the two separate weld joint zones compriselaser beam weld zones.
 8. The component of claim 1, wherein the twoseparate weld joint zones comprise friction stir weld zones.
 9. Thecomponent of claim 1, wherein the two side pieces are bent or orientedaway from each other by a total angle α, whereby inner surfaces of thetwo side pieces and a surface of the at least one panel form a generallyisosceles triangle.
 10. The component of claim 9, wherein the angle αlies in a range of between approximately 7° and approximately 50°. 11.The component of claim 1, wherein the two side pieces are bent ororiented at a total angle α of approximately 180°, whereby innersurfaces of the two side pieces rest on a surface of at least one panel.12. The component of claim 11, wherein the two side pieces areintegrally formed with the at least one stiffening element, whereby theat least one stiffening element and the two side pieces comprise aone-piece member.
 13. The component of claim 1, wherein the two sidepieces are integrally formed with the at least one stiffening element,whereby the at least one stiffening element and the two side piecescomprise a one-piece member.
 14. The component of claim 1, wherein theat least one stiffening element comprises a generally U-shaped profile,whereby the two side pieces are arranged on opposite ends of a head ofthe at least one stiffening element.
 15. The component of claim 14,wherein the two side pieces of the generally U-shaped profile areparallel to each other.
 16. The component of claim 1, wherein the atleast one stiffening element comprises an edge area which is oriented ina generally parallel manner relative to the at least one panel.
 17. Thecomponent of claim 1, wherein the at least one panel comprises a panelreinforcing base portion which comprises a first base portion and asecond base portion separated from the first base portion, whereinlateral outer surfaces of the first and second base portions restagainst or adjacent to inner surfaces of the two side pieces.
 18. Thecomponent of claim 1, wherein an area of the at least one panelcomprising the two weld joint zones comprises a surface formed by metalcutting.
 19. The component of claim 1, wherein an area of the at leastone panel comprising the two weld joint zones comprises a surface formedby metal removal.
 20. The component of claim 1, wherein at least one ofthe two side pieces comprises cut-outs.
 21. The component of claim 1,wherein at least one of the two side pieces comprises a plurality ofthrough openings.
 22. The component of claim 1, wherein each of the twoside pieces comprises cut-outs and wherein the cut-outs are arranged atgenerally regular intervals “a”.
 23. The component of claim 1, whereineach of the two side pieces comprises through openings arranged atgenerally regular intervals “a”.
 24. The component of claim 23, whereina distance between an edge of the through openings and joint surfaces ofthe two joint zones is greater than approximately one and a half times aside piece thickness t_(S) measured in a plane of each joint zone. 25.The component of claim 23, wherein the through openings in one of thetwo side pieces are spaced from each other by a distance “a” and whereinthe through opening of the other of the two side pieces are spaced fromthe through openings of the one of the two side pieces by a distance ofapproximately a/2.
 26. The component of claim 23, wherein the throughopenings comprise circular openings.
 27. The component of claim 23,wherein one of the through openings comprise polygonal openings and thethrough openings comprise non-circular openings.
 28. The component ofclaim 23, wherein the through openings comprise triangular openings. 29.The component of claim 28, wherein the triangular openings compriseapproximately equal-sided triangular openings with rounded corners, andwherein vertices of adjacent triangular openings point in oppositedirections.
 30. The component of claim 1, further comprising a doublerplate made of a damage-tolerant fiber-reinforced laminate attached toouter surfaces of the two side pieces.
 31. The component of claim 1,further comprising at least one stress relief element located inside theat least one panel.
 32. The component of claim 31, wherein the at leastone panel comprises a thickened panel base arranged in an area of thetwo separate joint zones and wherein the at least one stress reliefelement is arranged within the thickened panel base.
 33. The componentof claim 32, wherein the at least one stress relief element is arrangedbeneath a bar portion of the at least one stiffening element and betweenthe two separate joint zones.
 34. The component of claim 31, wherein theat least one stress relief element comprises a material having a highermodulus of elasticity and a higher fatigue strength than a material ofthe at least one panel.
 35. The component of claim 31, wherein the atleast one stress relief element comprises a plurality of stress reliefelements.
 36. The component of claim 31, wherein the at least one stressrelief element comprises a plurality of spaced apart stress reliefelements.
 37. The component of claim 31, wherein the at least one stressrelief element comprises a high-strength wire cable.
 38. The componentof claim 31, wherein the at least one stress relief element is locateddirectly beneath a panel stiffening base of the at least one panel andis centrally disposed between the two separate joint zones.
 39. Thecomponent of claim 37, wherein the panel stiffening base is integrallyformed with the at least one panel, whereby the panel stiffening baseand the at least one panel comprise a one-piece member.
 40. Thecomponent of claim 1, wherein the at least one panel comprises a panelstiffening base made of material that is deformed during a rolling-in ofa stress relief element into the at least one panel.
 41. The componentof claim 1, wherein the at least one panel comprises a panel stiffeningbase made of material that is deformed during a rolling of the at leastone panel.
 42. The component of claim 1, wherein the at least one panelcomprises a plurality of panel bars arranged generally parallel to oneanother and generally parallel to the at least one stiffening element.43. The component of claim 1, wherein the at least one panel comprises aplurality of panel bars arranged generally parallel to one another andgenerally perpendicular to the at least one stiffening element.
 44. Thecomponent of claim 1, wherein the at least one panel comprises aplurality of panel bars, some of which are arranged generally parallelto one another and some of which are arranged generally perpendicular toone another.
 45. The component of claim 1, wherein the at least onepanel comprises a plurality of panel stiffening bases and a plurality ofpanel bars, wherein a height of the panel bars generally corresponds toa height of the panel stiffening bases, wherein the at least onestiffening element comprises a plurality of stiffening elements, andwherein a spacing between the stiffening elements is generally equal toan integral multiple of a spacing “C” between the panel bars.
 46. Thecomponent of claim 1, wherein the at least one stiffening elementcomprises a head portion that is coupled to a bar portion.
 47. Thecomponent of claim 46, wherein the head portion projects from both sidesof the bar portion.
 48. The component of claim 47, wherein the headportion projects by generally equal amounts from both sides of the barportion.
 49. A lightweight structural component comprising: at least onemetal panel comprising at least one thickened region; at least one metalstiffening element welded to the at least one panel; the at least onemetal stiffening element comprising a bar portion and two side pieces;each side piece comprising an outer surface, an inner surface, and anend surface extending between the outer and inner surfaces and having awidth that is narrower than a length of the outer surface; and each endsurface of the two side pieces being at least partially connected in amaterial-locking manner to the at least one thickened region by twoseparate weld joint zones, whereby the at least one metal stiffeningelement is oriented in at least one of a lengthwise and a crosswisedirection.
 50. The component of claim 49, further comprising areinforcing element located in a cavity formed by the two side piecesand a surface of the at least one thickened region.
 51. The component ofclaim 50, wherein the at least one thickened region comprises a panelstiffening base and wherein the reinforcing element comprises ahigh-strength material having a modulus of elasticity that is generallygreater than a modulus of elasticity of a material of at least one ofthe at least one panel and the at least one stiffening element.
 52. Thecomponent of claim 51, wherein the reinforcing element is connected toat least one of the two side pieces and to the at least one panelstiffening base in one of a force-locking manner and a form-lockingmanner.
 53. The component of claim 49, wherein the component is arrangedon an aircraft.
 54. The component of claim 49, wherein the at least onestiffening element comprises a stringer oriented in a lengthwisedirection.
 55. The component of claim 49, wherein the at least onestiffening element comprises a rib oriented in a circumferentialdirection.
 56. The component of claim 49, wherein the two separate weldjoint zones comprise laser beam weld zones.
 57. The component of claim49, wherein the two separate weld joint zones comprise friction stirweld zones.
 58. The component of claim 49, wherein the two weld jointzones comprise panel surfaces and surfaces of the two side pieces, andwherein each of the panel and two side piece surfaces comprises amachined surface.
 59. The component of claim 49, further comprising areinforcing element having surfaces which are both force-locked andform-locked to at least one of inner surfaces of the two side pieces anda surface of the thickened region.
 60. The component of claim 59,wherein the surfaces comprise at least one of a rough profile andsurface profiling.
 61. The component of claim 49, further comprising areinforcing element which comprises surfaces which are fixed to at leastone of inner surfaces of the two side pieces and a surface of thethickened region.
 62. The component of claim 49, further comprising acavity formed by the two side pieces and the at least one thickenedregion and a reinforcing element arranged within the cavity.
 63. Thecomponent of claim 62, wherein a cross-sectional shape of the cavitygenerally corresponds to a cross-sectional shaped of the reinforcingelement.
 64. The component of claim 63, wherein the cavity comprises across-sectional shape having a form of a generally equal isoscelestriangle with a rounded-off apex.
 65. The component of claim 63, whereinthe reinforcing element comprises a cross-sectional shape having a formof a generally equal isosceles triangle with a rounded-off apex.
 66. Thecomponent of claim 49, further comprising at least one reinforcingelement arranged within the at least one thickened region.
 67. Thecomponent of claim 49, further comprising at least one reinforcingelement arranged between the two side pieces, wherein the at least onereinforcing element comprises one of a wire, a rod, a wire rope, a pipeand a tube.
 68. The component of claim 67, wherein the at least onethickened region comprises a curved surface and wherein the two sidepieces comprises curved inner surfaces, whereby the curved surfacesenclose the at least one reinforcing element.
 69. The component of claim68, wherein the two side pieces contact at least approximately 180° of acircumferential surface of the at least one reinforcing element.
 70. Thecomponent of claim 68, wherein the two side pieces comprise portionswhich are arranged parallel to one another, whereby a spacing betweeninner surfaces of the two side pieces generally corresponds to adiameter of the at least one reinforcing element.
 71. The component ofclaim 49, wherein the at least one thickened region comprises a panelstiffening base which contains a recess adapted to receive a reinforcingelement.
 72. The component of claim 49, further comprising a pluralityof cut-outs arranged in at least one of the bar portion and the two sidepieces, wherein the cut-outs are arranged at regular intervals “a”. 73.The component of claim 49, further comprising a plurality of throughopenings arranged in at least one of the bar portion and the two sidepieces, wherein the through openings are arranged at regular intervals“a”.
 74. The component of claim 49, further comprising a plurality ofthrough openings arranged in at least one of the bar portion and the twoside pieces.
 75. The component of claim 74, wherein the through openingscomprise a circular through openings.
 76. The component of claim 74,wherein the through openings comprise non-circular through openings. 77.The component of claim 74, wherein the through openings comprisepolygonal through openings.
 78. The component of claim 74, wherein thethrough openings comprise generally approximately equilateral triangularthrough openings with rounded-off corners.
 79. The component of claim78, wherein adjacent triangular through openings are oriented inopposite directions.
 80. The component of claim 74, wherein the throughopenings of one of the two side pieces are arranged offset from thethrough openings of another of the two side pieces, whereby a distancebetween the through openings of each of the two side pieces comprises avalue “a”, and whereby a distance between each of the through openingsof one of the two side pieces and each of the through openings ofanother of the two side pieces comprises a value of approximately a/2.81. The component of claim 49, further comprising a plurality of stressrelief elements arranged within the at least one thickened region. 82.The component of claim 81, wherein at least one of the plurality ofstress relief elements is arranged on one side of the bar portion andwherein at least another of the plurality of stress relief elements isarranged on another side of the bar portion.
 83. The component of claim81, wherein at least one of the plurality of stress relief elements isarranged near each of the two separate weld joint zones.
 84. Thecomponent of claim 81, wherein at least one of the plurality of stressrelief elements comprises a material having a higher modulus ofelasticity and a higher fatigue strength than a material of the at leastone panel.
 85. The component of claim 81, wherein at least one of thestress relief elements comprises a high-strength wire cable.
 86. Thecomponent of claim 49, wherein the at least one panel comprises a sheetskin for one of an aircraft, a boat and a ship.
 87. The component ofclaim 49, wherein the at least one panel comprises a plurality ofintegrally formed panel bars.
 88. The component of claim 87, wherein theplurality of panel bars are arranged generally parallel to the at leastone stiffening element.
 89. The component of claim 87, wherein theplurality of panel bars are arranged generally perpendicular to the atleast one stiffening element.
 90. The component of claim 87, wherein theplurality of panel bars are arranged generally parallel to one anotherand generally parallel to the at least one stiffening element.
 91. Thecomponent of claim 87, wherein a height of the panel bars corresponds toa height of the at least one thickened region.
 92. The component ofclaim 87, wherein the at least one stiffening element comprises aplurality of stiffening elements which are spaced apart from one anotherby an amount equal to an integral multiple of a spacing “C” of the panelbars.
 93. The component of claim 49, wherein the at least one stiffeningelement comprises a head which is centrally disposed on the bar portion.94. A method of producing the lightweight structural component of claim1, the method comprising: milling the at least one metal panel to format least one thickened region; and extruding the at least one metalstiffening element; subjecting the at least one metal panel to tension;subjecting the at least one metal stiffening element to tension; andjoining the two side pieces to the at least one thickened region at thetwo separate weld joint zones.
 95. A method of producing the lightweightstructural component of claim 1, the method comprising: milling the atleast one metal panel to form at least one thickened region; and joiningthe two side pieces of the at least one metal stiffening element to theat least one panel at the two separate weld joint zones.
 96. The methodof claim 95, further comprising extruding the at least one stiffeningelement.
 97. The method of claim 95, further comprising subjecting theat least one panel to tension.
 98. The method of claim 95, furthercomprising subjecting the at least one stiffening element to tension.99. The method of claim 95, wherein the joining comprises joining thetwo side pieces to the at least one thickened region by laser beamwelding.
 100. The method of claim 95, wherein the joining comprisesjoining the two side pieces to the at least one thickened region bylaser beam welding, and wherein a laser beam focus is formed such thatit is one of extended in a feed direction and divided into two partialbeams.
 101. The method of claim 95, wherein the joining comprisesjoining the two side pieces to the at least one thickened region byfriction stir welding.
 102. The method of claim 95, wherein the joiningcomprises simultaneously joining the two side pieces to the at least onethickened region.
 103. The method of claim 95, wherein the joiningcomprises unilaterally joining the two side pieces to the at least onethickened region.
 104. The method of claim 95, wherein the joiningcomprises joining the two side pieces one at a time to the at least onethickened region.
 105. The method of claim 95, further comprising,before the joining, forming the two side pieces by extrusion.
 106. Themethod of claim 95, further comprising extruding the at least onestiffening element and the two side pieces to form a one-piece extrudedmember.
 107. The method of claim 95, further comprising forming the atleast one stiffening element as an extruded rib, wherein the two sidepieces comprise inner curved surfaces, and wherein the thickened regioncomprises a curved surface.
 108. The method of claim 95, wherein themilling comprises chemical milling.
 109. The method of claim 95, whereinthe milling comprises mechanical milling.
 110. The method of claim 95,wherein the milling comprises HSC milling.
 111. The method of claim 95,further comprising extruding the at least one stiffening element andthereafter forming the two side pieces by splitting, whereby thesplitting utilizes press rollers.
 112. The method of claim 95, furthercomprising extruding the at least one stiffening element and thereafterforming the two side pieces by rolling.
 113. The method of claim 95,further comprising positioning a reinforcing element between the twoside pieces of the at least one stiffening element and a surface of theat least one thickened region.
 114. The method of claim 95, furthercomprising connecting a reinforcing element to at least one of the twoside pieces of the at least one stiffening element and a surface of theat least one thickened region.
 115. The method of claim 95, furthercomprising connecting by mechanical deformation a reinforcing element toat least one of the two side pieces of the at least one stiffeningelement and a surface of the at least one thickened region.
 116. Themethod of claim 115, wherein the mechanical deformation comprisesrolling-in.
 117. The method of claim 114, wherein the connectingcomprises at least one of force-locking and form-locking connecting.118. The method of claim 95, further comprising forming by co-extrusionthe at least one stiffening element and a reinforcing element.
 119. Themethod of claim 95, further comprising, before the joining, tensioningat least one of the at least one stiffening element and the at least onepanel.
 120. The method of claim 95, further comprising, during thejoining, tensioning at least one of the at least one stiffening elementand the at least one panel.
 121. A method of producing the lightweightstructural component of claim 49, the method comprising: milling the atleast one metal panel to form the at least one thickened region; andjoining the two side pieces to the at least one thickened region at thetwo separate weld joint zones.
 122. A method of producing thelightweight structural component of claim 49, the method comprising:milling the at least one metal panel to form the at least one thickenedregion; forming as a one-piece member the at least one metal stiffeningelement and the two side pieces; and joining the two side pieces to theat least one thickened region at the two separate weld joint zones. 123.A lightweight structural component comprising: a metal panel comprisingat least one thickened region; at least one stiffening element coupledto a surface of the at least one thickened region; the at least onestiffening element being a one-piece metal member and comprising a headportion, a bar portion and two side pieces extending from the barportion; the bar portion comprising a first thickness; each of the twoside pieces comprising a second thickness; the first thickness beinggreater than the second thickness; and end surfaces of the two sidepieces being at least partially connected to the at least one thickenedregion by two separate weld joint zones, wherein each of the two sidepieces comprises an outer surface and an inner surface and wherein eachend surface has a width that is narrower than a length of the outersurface when measured between the bar portion and the end surface. 124.The component of claim 123, wherein the bar portion and two side piecesof the at least one stiffening element form a generally Y-shapedcross-section.
 125. The component of claim 123, wherein the bar portionand two side pieces of the at least one stiffening element form agenerally T-shaped cross-section.
 126. The component of claim 123,wherein the at least one stiffening element has a generally I-shapedcross-section.
 127. The component of claim 123, wherein a distancebetween the two separate weld joint zones is greater than the firstthickness.
 128. The component of claim 123, wherein a distance betweenthe two separate weld joint zones is greater than the second thickness.129. The component of claim 123, wherein a distance between inner edgesof the two separate weld joint zones is greater than the firstthickness.
 130. The component of claim 123, wherein a distance betweeninner edges of the two separate weld joint zones is greater than thesecond thickness.
 131. The component of claim 1, wherein the twoseparate weld joint zones are arranged between a thickened region of thepanel and the two side pieces.
 132. The component of claim 131, whereinthe at least one metal stiffening element comprises a one-piece metalmember.